Power converter

ABSTRACT

A power inverter comprises a plurality of high power switching modules that form an alternating current (AC) output; a plurality of terminals in communication with the high power switching modules for outputting the AC output; a capacitor bank that provides a conditioned voltage to the high power switching modules for producing the AC output in response to receiving and storing electrical energy related to a direct current (DC) supply; and a case positioned over the high power switching modules. The capacitor bank is mounted to the case, and the capacitor bank is positioned over the high power switching modules so that the high power switching terminals are proximal the capacitor bank for reducing inductance. A gate driver module at a top region of the high power switching modules includes a plurality of planar transformers for reducing a distance between the capacitor bank and the gate driver.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/398,756 filed Jan. 5, 2017 and entitled “Power Converter”, whichclaims the benefit of U.S. Provisional Patent Application No. 62/274,872filed Jan. 5, 2016 and entitled “Power Inverter,” the contents of eachof which is incorporated herein in their entirety.

FIELD

The present concepts relate generally to power converters, and morespecifically, to packaging and component arrangements for a powerconverter.

BACKGROUND

Power inverters are well-known for receiving electrical power from agenerator or other power source, and conditioning the electrical powersuch as converting the received power from direct current (DC) toalternating current (AC), AC to DC, or DC to DC at a different voltage.Issues related to high inductance may occur between components of aconventional power converter.

BRIEF SUMMARY

In one aspect, provided is a power inverter, comprising: a plurality ofhigh power switching modules that form an alternating current (AC)output; a plurality of terminals in communication with the high powerswitching modules for outputting the AC output; a capacitor bank thatprovides a conditioned voltage to the high power switching modules forproducing the AC output in response to receiving and storing electricalenergy related to a direct current (DC) supply; and a case positionedover the high power switching modules, wherein the capacitor bank ismounted to the case, and the capacitor bank is positioned over the highpower switching modules so that the high power switching terminals areproximal the capacitor bank.

In another aspect, provided is a power inverter, comprising: a pluralityof high power switching modules that form an alternating current (AC)output, the high power switching modules including a plurality ofterminals for outputting the AC output; a capacitor bank that provides aconditioned voltage to the high power switching modules for producingthe AC output in response to receiving and storing electrical energyrelated to a direct current (DC) supply; and a gate driver module at atop region of the high power switching modules, the gate driver moduleincluding a plurality of planar transformers for reducing a distancebetween the capacitor bank and the gate driver.

In another aspect, provided is a power converter, comprising: aplurality of insulated gate bipolar transistor (IGBT) modules thatconvert one form of electrical current to another form of electricalcurrent according to an operating mode; a plurality of terminals foroutputting the converted form of electrical current; and a gate drivermodule at a top region of the high power switching modules, the gatedriver module including a plurality of planar transformers.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The above and further advantages may be better understood by referringto the following description in conjunction with the accompanyingdrawings, in which like numerals indicate like structural elements andfeatures in various figures. The drawings are not necessarily to scale,emphasis instead being placed upon illustrating the principles of theconcepts.

FIG. 1A is an isometric view of a converter, in accordance with someembodiments.

FIG. 1B is a front view of the converter of FIG. 1A.

FIG. 1C is a side view of the converter of FIGS. 1A and 1B.

FIG. 1D is a top view of the converter of FIGS. 1A-1C.

FIG. 1E is an exploded front view of the converter of FIGS. 1A-1D.

FIG. 1F is an exploded side view of the converter of FIGS. 1A-1E.

FIG. 1G is a perspective view of a terminal side of the converter ofFIGS. 1A-1F.

FIG. 1H is another perspective view of the converter of FIGS. 1A-1G.

FIG. 2 is an isometric view of a cold plate, in accordance with someembodiments.

FIG. 3 is an isometric view of an insulated gate bipolar transistor(IGBT) module, in accordance with some embodiments.

FIG. 4 is an isometric view of a gate driver board, in accordance withsome embodiments.

FIG. 5 is an isometric view of a capacitor bank, in accordance with someembodiments.

FIG. 6A is an isometric view of the IGBT module and gate board module ofFIGS. 1A-1F, 3, and 4 separate from each other.

FIG. 6B is an isometric view of the IGBT module and gate board module ofFIGS. 1A-1F, 3, 4, and 6A coupled together.

FIG. 6C is a side view of the IGBT module and gate board module of FIGS.1A-1F, 3, 4, 6A, and 6B separate from each other.

FIG. 6D is a side view of the IGBT module and gate board module of FIGS.1A-1F, 3, 4, and 6A-6C coupled together.

FIG. 7 is a top view of the IGBT module and gate board module of FIGS.1A-1F, 3, 4, and 6A-6D coupled together.

FIG. 8A is a front view of the IGBT module, gate board module, and coldplate of FIGS. 1-7 separate from each other.

FIG. 8B is a front view of the IGBT module, gate board module, and coldplate of FIGS. 1-8A coupled together.

FIG. 8C is an isometric view of the IGBT module, gate board module, andcold plate of FIGS. 1-8B separate from each other.

FIG. 8D is an isometric view of the IGBT module, gate board module, andcold plate of FIGS. 1-8C coupled together.

FIG. 8E is a side view of the IGBT module, gate board module, and coldplate of FIGS. 1-8D separate from each other.

FIG. 8F is a side view of the IGBT module, gate board module, and coldplate of FIGS. 1-8E coupled together.

FIG. 8G is a top view of the IGBT module, gate board module, and coldplate of FIGS. 1-8F.

FIG. 9 is an exploded isometric view of an converter, in accordance withother embodiments.

FIGS. 10A-10K are isometric views of steps of a method for assembling anconverter, in accordance with some embodiments.

FIG. 11 is a view of a gate driver, in accordance with some embodiments.

FIG. 12A is a view of a DC+ busbar, in accordance with some embodiments.

FIG. 12B is a view of a DC− busbar, in accordance with some embodiments.

FIG. 13 is a view of a gate board module, in accordance with someembodiments.

FIG. 14 is a graph showing an effect of spacing between a gate drive anda capacitor bank on a DC Bus inductance and a maximum switchingfrequency of a converter, in accordance with some embodiments.

DETAILED DESCRIPTION

FIG. 1A is an isometric view of a power converter 10, in accordance withsome embodiments. FIG. 1B is a front view of the converter 10 of FIG.1A. FIG. 1C is a side view of the converter 10 of FIGS. 1A and 1B. FIG.1D is a top view of the converter 10 of FIGS. 1A-1C. FIG. 1E is anexploded front view of the converter 10 of FIGS. 1A-1D. FIG. 1F is anexploded side view of the converter 10 of FIGS. 1A-1E. FIGS. 2-5 areviews of various elements of the converter 10. FIGS. 6A-6E, 7, and 8A-8Gare views of assemblies of various elements of the converter 10.

The converter 10 can convert a DC input into AC, which may be outputfrom the converter 10 via terminals 123 positioned in terminal blocks121. In other embodiments, the converter 10 may convert an AC input intoDC. In other embodiments, the converter 10 may convert a DC input intoDC. Thus, terminals 123 may be AC output terminals in an inverter mode(DC/AC), AC inputs in a rectifier mode (AC/DC), or DC outputs for aDC/DC mode. Accordingly, one or more of the foregoing modes, and/orother related operation modes, may be offered. The terminal blocks 121may be coupled to a substrate or related sheet on which the cold plate125 and other elements of the converter 10 may be positioned.

In some embodiments, the converter 10 comprises an array of capacitors110, a plurality of high power switching modules 130, for example,insulated gate bipolar transistor (IGBT) modules, or related solid statedevices, and a gate driver board 140, or module or other relatedconfiguration. The capacitor array 110 may be mounted to a frame or case120 shown in FIG. 10C, for positioning over the IGBTs 130. As describedherein, the IGBTs 130 can be positioned on a cold plate, heat sink 125,or related heat dissipation surface.

The capacitors in the array 110 may be film capacitors, electrolyticcapacitors, or the like for receiving a source of DC, storing a chargecorresponding to the received source of DC, and providing a conditionedvoltage, which is used by the IGBTs 130 to produce an AC output. The DCsource may be a known source such as a battery, power grid, alternativepower source, rectifier, and so on. The capacitors 110 may have acylindrical, rectangular, or other configuration. The capacitors 110 mayhave a same, similar, or different configuration with respect to eachother. The capacitors in the array 110 are constructed and arranged forproviding a total capacitance suitable for charging and dischargingaccording to power requirements imposed on the converter 10.

In some embodiments, the IGBTs 130 function as high power switches.Although IGBTs are shown and described, other high power semiconductorswitching devices can equally apply. The 130 include a plurality ofconnectors or terminals 132, for example, single for coupling a DC+ busbar 111A and DC− bus bar 111B (see FIGS. 12A and 12B) to the IGBTs 130.AC terminals 123 are also provided.

The gate driver board 140 is coupled to the gates of the IGBTs 130. Anexternal controller (not shown) can provide control signals to the gatedriver board 140 so that the gate driver board 140 can control theoperating mode of the IGBTs 130, for example, convert the DC voltageapplied from the capacitor bank 110 to AC, where resulting AC is outputfrom the converter 10 via AC terminals 123, or other operating modeswhere the IGBTs 130 convert an AC input into DC, or convert a DC inputinto DC. The controller may be include a special purpose computerprocessor and memory for processing signals that are output to the IGBTs130 for performing a conversion function according to an operating modeidentified in the received signals. For example, the signals may includeelectronic data that indicate whether the operating mode instructs theIGBTs 130 to perform a DC to AC conversion, AC to DC conversion, and/ora DC to DC conversion. Thus, a same hardware apparatus may be used tocapture multiple operating modes.

In embodiments where the IGBTs 130 convert a received DC voltage to AC,output terminals 111A, 111B (see FIG. 5) are referred to as DC outputterminals for exchanging DC signals with the capacitor bank 110. In someembodiments, DC output terminals 111A, 111B are part of a DC+ busbar andDC− busbar, respectively. As shown in FIG. 11, the gate driver board 140can include a control connector 146, which is used to pass the switchingsignals to the gate driver and pass state information back to thecontroller. The controller may generate signals that command the gatedriver to open and close the IGBT modules 130, and can process receivedsignals regarding device temperature, voltage, or the like for a desireduser purpose. The DC− busbar 111B may be coupled to the gate driverboard 140 by one or more connectors 141, for example, screws.

The IGBTs 130 may be mounted to the cold plate 125. The cold plate 125is preferably a liquid cooling cold plate that provides a flow pathprovided by coolant fittings 131 that move liquid under the IGBTs 130.The capacitors 110 and IGBTs 130 may generate a significant amount ofheat. After heat generated by these components, and possibly othercomponents of the converter 10, is absorbed into the liquid, the heatedliquid is removed via cooling fitting 131 coupled to an attached hose(not shown). Cooling fluid may include water and/or other refrigerantliquid. In some embodiments, the IGBTs 130 can be positioned on an aircooled heat sink, instead of a liquid cooled heat sink.

The gate driver board 140 preferably includes planar transformers 142(see for example FIG. 13) etched into the board instead of discretecomponents, and uses a single edge connector and serial communicationsto eliminate the need to access to the top of the board. This allows fora low inductance connection between capacitors 110 and IGBTs 130. Thetransformer may or may not include a core. In particular, it isdesirable to position capacitors 110 close to the IGBTs 130 to limitinductance between electrical conductors of the invertor 10. At regionas shown in FIG. 1A, inductance may be reduced between the capacitors110 and IGBT terminals. As shown in FIGS. 1B and 13, the presence ofplanar transformers permit a reduced distance (d) between the gatedriver board 140 and the capacitor bank 110.

FIG. 9 is an exploded isometric view of an inverter 200, in accordancewith other embodiments.

FIGS. 10A-10K are isometric views of steps of a method for assembling aninverter 300, in accordance with some embodiments. The inverter 300 maybe generally similar to inverters 10 and 200 described herein, but mayinclude some differences with respect to the shape, configuration,and/or function of its components, and/or the presence or absence ofcomponents.

At FIG. 10A, three IGBTs 130 are coupled to a cold plate 125, forexample, using screws or other coupling devices. Thermal grease or thelike may applied to the IGBTs 130 as part of the installation.

At FIG. 10B, a gate driver board 140 is coupled to the IGBTS 130. Thiscan be achieved by press-fit pins 136 or related coupling mechanismsaligned with the gate driver board 140. The gate driver board 140 can bescrewed into the IGBTs.

At FIGS. 10C and 10D, a plurality of terminal blocks 121 are insertedinto a case 120, for example, in notches, openings, or the like in thecase 120, and coupled to the case 120, for example, using screws, orother fastening devices. In other embodiments, for example, shown inFIGS. 1A-1F, the terminal blocks 121 may be coupled to a substrate orrelated sheet on which the cold plate 125 and other elements of theinverter are coupled.

At FIG. 10E, the combination of cold plate 125 and IGBTs 130, and gatedriver module, or board, 140 is coupled to the case 120. As shown inFIGS. 4, 9, and 10B-10K, the gate driver module 140 may include currentsensor areas constructed as extensions 143 or the like that align withand are inserted in the terminal blocks 121. Here, the gate drivermodule 140 can include three IGBT modules and process current sensingfor five output terminals at the extensions 143, or protrusions, butthis configuration is not limited thereto. In other embodiments, forexample shown in FIGS. 6-8, the gate driver module 140 has a rectangularshape. The extensions 143 incorporate current sensing functions, and mayapply to both DC connections and the connections. At FIG. 10F, theterminal blocks 121 may include output terminals 123, referred to as ACterminals, and for outputting a voltage and current from the converter10. The AC terminals 123 are coupled to the IGBTs 130, for providing anelectrical path from the IGBTs to the AC terminals 123. At FIG. 10G, ACcurrent sensor shields 126 and insulators 127 are installed on the ACterminals 123. The insulators isolate output voltage from signal levelsystems and the shields concentrate the magnetic flux and reducecrosstalk to improve sensor performance.

At FIG. 10H, a capacitor bank mount 135 is installed, which providesmechanical support. At FIG. 10I, a capacitor bank 110 is installed, orcoupled to the capacitor bank mount 135. The capacitor bank 110 andcapacitor bank mount 135 in turn are coupled to the case 120, forexample, using screws or other coupling devices, adhesives, and so on.Here, a DC+ busbar and DC− busbar are positioned in two remainingterminal blocks 121 not occupied by the AC terminals 123. Outputterminals of the DC+ busbar 111A and DC− busbar 111B, respectively, arereferred to as DC terminals for exchanging DC signals with the capacitorbank 110. At FIG. 10J, DC current sensor shields 126 and insulators 127are installed in the terminal blocks 121 over the DC+ busbar 111A andDC− busbar 111B, and may be similar as the sensor shields 126 andinsulators 127 of FIG. 10G. This configuration permits inductance to bereduced between the capacitors 110 and IGBT due to the short distancebetween the capacitors 110 and IGBT terminals.

At FIG. 10K a top cover 145 is installed, or more specifically, coupledto the case 120 using screws, adhesives, or other coupling devices.

FIG. 14 is a graph showing an effect of spacing between a gate drive anda capacitor bank on a DC Bus inductance and a maximum switchingfrequency of a converter, in accordance with some embodiments. Higherfrequencies allow for cleaner output waveforms and exceeding the maximumshown in the graph plot may create a destructive resonance within theconverter. A benefit of improving inductance is that this inductance maycreate a voltage spike across the switching device when is inactive, forexample, it turns off. Reducing the inductance in this manner mayproportionally reduce the undesirable spike, improving the lifetime ofthe switch and reducing electromagnetic interference (EMI) output fromthe device.

While concepts have been shown and described with reference to specificpreferred embodiments, it should be understood by those skilled in theart that various changes in form and detail may be made therein withoutdeparting from the spirit and scope as defined by the following claims.

What is claimed is:
 1. A power inverter, comprising: a plurality of highpower switching modules that form an alternating current (AC) output,the high power switching modules including a plurality of terminals foroutputting the AC output; a capacitor bank that provides a conditionedvoltage to the high power switching modules for producing the AC outputin response to receiving and storing electrical energy related to adirect current (DC) supply, the capacitor bank constructed and arrangedto extend along a first plane; and a gate driver module between the highpower switching modules and the capacitor bank and extending along asecond plane parallel the first plane, the gate driver module includinga plurality of planar transformers for reducing a distance between thefirst plane of the capacitor bank and the second plane of the gatedriver module.
 2. The power inverter of claim 1, further comprising acase positioned over the high power switching modules, wherein thecapacitor bank is mounted to the case for separating the first plane ofthe capacitor bank and the second plane of the gate driver module by thereduced distance.
 3. The power inverter of claim 1, wherein the highpower switching modules include insulated gate bipolar transistor (IGBT)modules.
 4. The power inverter of claim 1, further comprising a bus barextending over the gate driver module and separating the capacitor bankfrom the gate driver module to reduce inductance between the capacitorbank and the high power switching modules.
 5. The power inverter ofclaim 4, further comprising a plurality of sensor shields and insulatorsover the bus bar.
 6. A power converter, comprising: a plurality ofinsulated gate bipolar transistor (IGBT) modules that convert one formof electrical current to another form of electrical current according toan operating mode; a plurality of terminals for outputting the convertedform of electrical current; and a gate driver module at a top region ofthe high power switching modules; and a capacitor bank that provides aconditioned voltage to the IGBT modules for producing an AC output inresponse to receiving and storing electrical energy related to a directcurrent (DC) supply, wherein the gate driver module includes a pluralityof planar transformers for reducing a distance between a first plane ofthe capacitor bank and a second plane of the gate driver module parallelthe first plane.
 7. The power converter of claim 6, wherein theoperating mode is an inverter operating mode, wherein the IGBT modulesoutputs an alternating current (AC) in response to a received source ofdirect current (DC).
 8. The power converter of claim 6, wherein theoperating mode is a rectifier operating mode, wherein the IGBT modulesoutputs a direct current (DC) in response to a source of alternatingcurrent (AC).
 9. The power converter of claim 6, wherein the operatingmode is a DC/DC operating mode.
 10. The power converter of claim 6,wherein the gate driver receives command signals from an externalcontroller, and wherein the command signals are used by the IGBT modulesto establish the operating mode.
 11. A power inverter, comprising: aplurality of high power switching modules that form an alternatingcurrent (AC) output; a capacitor bank that provides a conditionedvoltage to the high power switching modules for producing the AC outputin response to receiving and storing electrical energy related to adirect current (DC) supply, the capacitor bank constructed and arrangedto extend along a first plane; a gate driver module between the highpower switching modules and the capacitor bank and extending along asecond plane parallel the first plane; and a case positioned over thehigh power switching modules, wherein the capacitor bank is mounted tothe case, and positioned over the high power switching modules so thatthe high power switching terminals are proximal the capacitor bank. 12.The power inverter of claim 11, further comprising a cold plate or heatsink on an opposite side of the case as the capacitor bank, wherein thehigh power switching modules are positioned on the cold plate or heatsink.
 13. The power inverter of claim 11, wherein the gate driver modulecomprises a control connector that exchanges signals between the gatedriver module and a controller.
 14. The power inverter of claim 11,further comprising a DC bus bar, wherein the high power switchingmodules are on a first side of the DC bus bar and the capacitor bank ison the other side of the DC bus bar.
 15. The power inverter of claim 14,wherein the DC bus bar extends over the gate driver module and separatesthe capacitor bank from the gate driver module to reduce inductancebetween the capacitor bank and the high power switching modules.
 16. Thepower inverter of claim 1, further comprising a plurality of terminalblocks coupled to the case, wherein a combination of AC output terminalsin communication with the high power switching modules and DC outputterminals in communication with the capacitor bank are positioned in theterminal blocks.